Volvo Penta TAD532GE Engine

⚠ Only tighten the stop screw gently by hand.

Tools: Measuring fixture 999 8684, Rule depth gauge 998 5471, Pressure tool 999 8682

1. Turn the engine through 180° and attach measuring fixture 999 8684 on the leading edge of the engine.
2. Measure from the measuring fixture to the control rod stop position with rule depth gauge 998 5471.
3. Measure from the measuring fixture to the control rod start position.
4. The difference between start and stop positions is the control rod travel.
5. Turn the measuring fixture and push the control rod to the stop position by hand using the stop screw.

⚠ Fuel pressure jet can penetrate deep into skin tissue and cause blood poisoning.

⚠ Use only clean test oil meeting ISO 4113 or clean diesel.

Tools: Nozzle tester, Injector microscope, Ultrasonic cleaner

1. Connect the injector to the nozzle tester.
2. Check the opening pressure; control value in Technical data.
3. Check leak-down: pressure may at most drop to 5 MPa / 5 sec.
4. Hold 2 MPa below opening pressure for 10 s; no drips permitted.
5. Take off the cap nut and remove all parts.
6. Wash details in an ultrasonic cleaner or washing petrol/Vanolen.
7. Inspect injector details using an injector microscope.
8. Dip parts in oil before assembly.
9. Set pressure by selecting an appropriate shim; thicker shim increases opening pressure.
10. Tighten the cap nut to 40 ±5 Nm and recheck in the nozzle tester.
11. Check seal and perform chatter characteristic / spray pattern test.

Tools: Feeler gauge, Rotating tool 999 8676, Cranking tool 999 8681

1. Set valve clearance with the engine cold or cooled at least half an hour (oil temp < 80 °C).
2. Rotate the crankshaft until the valves of cylinder 1 overlap.
3. Set the valve clearance for each cylinder with a feeler gauge per the black markings.
4. Inlet 0.35 ±0.05 mm; exhaust 0.55 ±0.05 mm.
5. Tighten the locknut to 20 ±2 Nm and recheck with the feeler gauge.
6. Rotate the crankshaft another 360° and repeat for the remaining cylinders.
7. Fit a new rocker cover gasket.

⚠ Make sure that the fuel control rod is in the no fuel position (stop position).

Tools: Adapter 999 8694, Compression gauge 998 8539

1. The injectors must be removed and the valve clearance checked.
2. Fit adapter 999 8694, using the existing injector yoke.
3. Tighten the screw to 19 ±2 Nm.
4. Connect the compression tester 998 8539.
5. Turn the engine over with the starter motor.
6. Make sure the fuel control rod is in the no-fuel (stop) position.
7. Compare cylinders; dismantle the cylinder if the pressure difference exceeds 15%.

⚠ The injectors are sensitive and may easily be damaged by contamination.

Tools: Manometer 999 6398, Nipple 999 6066, Hollow screw 180211, Copper washer 969011, Electrical pressure gauge 999 8496, Hose 999 8493

1. Clean the nipple and hose thoroughly before connecting them.
2. Check the fuel pump and replace if necessary.
3. Measure the supply pressure before (1) and after (2) the fuel filter.
4. Use manometer 999 6398, nipple 999 6066 with hollow screw 180211 and new copper washers 969011.

Tools: Manometer 999 6398, Nipple 999 6066, Spacer 1678297, Electrical pressure gauge 999 8496, Hose 999 8493

1. Measure the lubricating oil pressure on the starter motor side of the engine.
2. Use the manometer together with nipple and spacer.
3. Compare the reading with the minimum oil pressure at operating temperature and idle speed.

⚠ The oil cooler may not be repaired.

⚠ The oil cooler should be the same temperature as the surroundings during the check.

Tools: Pressure-testing equipment 999 6662, Clamp for cooler 999 6685, Plug M26x1.5 942352

1. Place a clamp on the oil cooler and make sure it is properly tightened.
2. Plug the other connection.
3. Connect the pressure-testing equipment.
4. Place the oil cooler in a tub of water.
5. Set the air pressure to 100 kPa and check for air bubbles.
6. Increase the pressure to 500 kPa and hold for 1 minute; pressure may not drop.
7. If pressure drops there is a leak and the oil cooler must be replaced.

1. Model 1: remove the coolant pump from the housing and remove the V-belt pulley.
2. Check coolant pump and sealing for leaks; replace if necessary.
3. Fit the V-belt pulley and tighten bolts to 21 Nm.
4. Fit the coolant pump in the housing with a new gasket.
5. Model 2: loosen the coolant pump from the housing and remove the V-belt pulley.
6. Check coolant pump and sealing for leaks; replace if necessary.
7. Make sure the overflow hole for the spindle seal is not filled up.
8. Fit the V-belt pulley and tighten bolts to 21 Nm.
9. Fit the coolant pump in the housing with a new gasket.

⚠ Do not over-tighten the belt, as it might damage the bearing in the fuel pump.

⚠ Replace the drive belt guard.

1. Only check, tension or change the drive belt when the engine is stopped.
2. Replace drive belts that are oily, worn or damaged.
3. Coolant/fuel pump: loosen screws 1 and 2.
4. Push the fuel pump (3) in direction A until correct belt tension.
5. Retighten screws 1 and 2.
6. Alternator: loosen screws 1, 2 and 3.
7. Push the alternator in the direction of the arrow until correct belt tension.
8. Retighten screws 1, 2 and 3; replace the drive belt guard.

Tools: Water bath

1. Push the thermostat down, turn it and take it out of the thermostat housing.
2. Test the thermostat function and replace if necessary.
3. Push the thermostat down into the housing and turn it; the securing yoke must engage.
4. Measure dimension a (starts to open) and b (completely open).
5. Heat the thermostat in a water bath, stirring continuously; temperature should not rise more than 1 °C/min.
6. When completely open, the difference between a and b should be at least 8 mm.

⚠ The pump is spring-loaded; if the tappet is not on the base circle the threads in the engine block can be damaged.

⚠ A delivery pipe which has been removed should be replaced with a new one.

Tools: 999 8684, Socket 11668403, Torque wrench with gauge

1. Clean the engine thoroughly before removing the rocker cover.
2. Remove the plug and install tool 999 8684; adjust the control rod to stop position.
3. Make sure the roller tappet for the pump is on the camshaft base circle.
4. Loosen the pump screws a couple of turns and tap the pump gently.
5. Remove the shim in the roller tappet and cover the hole.
6. Read the EP code from the engine identification plate and enter into Calculation 1.
7. Read corrected dimension Ek from Table 3; read L0 from Table 1; read A/100 from the pump.
8. Calculate theoretical shim thickness Ts = Ek – (L0 + A/100).
9. Read actual shim thickness Ss from Table 2 and slide the shim into place.
10. Turn the pump linkage lever to middle position, oil the O-rings and insert the pump.
11. Fit the pump flange with the chamfered hole facing the pump and pre-load screws to 5 Nm, then slacken 60°.
12. Use socket 11668403 and a torque wrench with gauge to turn the pump counterclockwise to its stop.
13. Tighten the flange screws 60°, then alternately 7, 10 and 30 Nm starting with the screw remote from the flywheel.
14. Remove tool 999 8684 and check that the fuel rack moves freely.
15. Pre-tension the delivery pipe in two stages 5 Nm then 25 ±3.5 Nm; fit new rocker cover gasket.

⚠ Fit the liner without sealer, well cleaned and dry.

Tools: Cylinder liner extractor 999 6645, Extractor plate 999 8675, Supports 999 6395, 999 6394

1. Ensure the cylinder liner area and liner sealing surfaces are completely clean.
2. Oil the engine block and cylinder liner in the marked areas.
3. Fit new O-rings; check the liner height compared with the engine block.
4. Fit the cylinder liner into the correct position in the engine block.
5. Drive it in as far as possible.